US8420564B2 - Sulfur-tolerant catalyst prepared through high pressure decomposition - Google Patents

Sulfur-tolerant catalyst prepared through high pressure decomposition Download PDF

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US8420564B2
US8420564B2 US13/236,326 US201113236326A US8420564B2 US 8420564 B2 US8420564 B2 US 8420564B2 US 201113236326 A US201113236326 A US 201113236326A US 8420564 B2 US8420564 B2 US 8420564B2
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decomposition
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sulfur
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Madhu Anand
Joe D. Allison
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Phillips 66 Co
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    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G39/00—Compounds of molybdenum
    • C01G39/06—Sulfides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/066—Zirconium or hafnium; Oxides or hydroxides thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
    • B01J27/02—Sulfur, selenium or tellurium; Compounds thereof
    • B01J27/04—Sulfides
    • B01J27/047—Sulfides with chromium, molybdenum, tungsten or polonium
    • B01J27/051—Molybdenum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61—Surface area
    • B01J35/613—10-100 m2/g
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61—Surface area
    • B01J35/615—100-500 m2/g
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0201—Impregnation
    • B01J37/0203—Impregnation the impregnation liquid containing organic compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment
    • B01J37/082—Decomposition and pyrolysis
    • B01J37/088—Decomposition of a metal salt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment
    • B01J37/10—Heat treatment in the presence of water, e.g. steam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/16—Reducing
    • B01J37/18—Reducing with gases containing free hydrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/20—Sulfiding

Definitions

  • a sulfur-tolerant catalyst prepared through high pressure decomposition.
  • MoS 2 and other sulfur tolerant catalysts based on the transition elements find wide application in the processing of hydrocarbon feedstock's particularly in methanation if they possess sufficient high activity.
  • nickel based catalysts are used in methanation because of their high activity, but they are extremely sensitive to deactivation by surface carbon, high temperature and poisoning by various sulfur compounds present in synthesis gas obtained from coal gasification.
  • Sulfur-tolerant MoS 2 catalyst can overcome many of the restrictions associated with nickel catalyst.
  • a recent economic study by Fluor compared sulfur-tolerant methanation with conventional methanation found a 3% reduction in the total plant investment and a 4.5% reduction in the cost of the substitute natural gas plant.
  • the most active sulfur-tolerant catalyst found for methanation in the literature is a MoS 2 catalyst initially developed by the Gas Research Institute.
  • a method of producing a MoS 2 catalyst begins by the decomposition of ammonium tetrathiomolybdate in an organic solvent. This decomposition is done in the presence of a solution comprising: a solvent and a promoter, and done under gaseous pressure.
  • An embodiment is also taught of producing a MoS 2 catalyst by first decomposition of ammonium tetrathiomolybdate in an organic solvent in the presence of a solution.
  • the solution contains a solvent of water and a promoter comprising zirconium and elemental sulfur.
  • the temperature of the decomposition is from 275° C. to 475° C. and the pressure the decomposition occurs under a H2 gaseous pressure from 2000 psig to 3000 psig.
  • the MoS 2 catalyst has a total CO conversion in synthesis gas methanation greater than 75%.
  • FIG. 1 demonstrates CO conversion of a MoS 2 catalyst wherein the gaseous pressure is greater than 2000 psig.
  • FIG. 2 demonstrates CO conversion of a MoS 2 catalyst produced by conventional means.
  • the present embodiment describes a method to produce a MoS 2 catalyst.
  • the method begins with the decomposition of ammonium tetrathiomolybdate in an organic solvent in the presence of a solution.
  • the solution can contain a solvent and a promoter.
  • the decomposition occurs under gaseous pressure.
  • a non-limiting example of the solvent used is H 2 O.
  • the promoter contains at least one metal and at least one element from group 16.
  • the metal can be a group 4 metal or specifically zirconium.
  • the element from group 16 can be sulfur.
  • the ratio of the metal to the at least one element is equal to the molar ratio of the desired MoS 2 catalyst.
  • the temperature of the decomposition is within the range of supercritical water such as from 275° C. to 475° C.
  • the gaseous pressure of the decomposition is within the range of supercritical water such as greater than 2000 psig or from 2000 psig to 3000 psig.
  • the gaseous pressure can be from H 2 of N 2 gas.
  • the use of a sulfur toleration catalyst shows significant improvements over conventional methanation because the MoS 2 catalyst is more carbon and sulfur tolerant.
  • the total CO conversion though use of the present embodiment can achieve in the synthesis gas methanation greater than 75%, 78% or even 80%.
  • the organic solvent can be any known organic solvent capable of keeping the ammonium tetrathiomolybdate in solution.
  • the solvent can be tridecane.
  • the MoS 2 catalyst methanates the raw syngas directly using equal molar concentrations of carbon monoxide and hydrogen to form carbon dioxide and water and does not need a water gas shift reaction to increase the syngas ratio resulting in steam usage savings. Since the MoS 2 catalyst is sulfur tolerant, sulfur impurities have to be removed only to 4 ppm levels instead of conventional 20 ppb levels to fulfill the requirements of pipeline natural gas. This in turn permits the acid gas removal unit to be smaller.
  • a MoS 2 catalyst was prepared by the decomposition of ammonium tetrathiomolybdate in an organic solvent such as tridecane in the presence of a solvent of water and dimethyl disulfide.
  • an organic solvent such as tridecane
  • different types of sulfur can be used as a sacrificial donor to prevent hydrogen from stripping all the sulfur from the MoS 2 catalyst in the form of H 2 S.
  • Other sacrificial sulfur donors that can be used include those commonly known in the art and diethyl disulfide, methyl mercaptan and tetrahydrothiophene.
  • the method begins by loading a 500 mL autoclave with the catalyst precursor ammonium tetrathiomolybdate (4 mg), 60 grams of the organic solvent of n-tridecane and 50 grams of water.
  • the Mo catalyst was modified with a zirconium promoter by adding 1.776 grams of zirconyl hydrate nitrate. 1 gram of dimethyl disulfide was added to prevent hydrogen from stripping all the sulfur from the MoS 2 catalyst. 1.538 grams of elemental sulfur was added for catalyst stability.
  • the sealed reactor was purged with H 2 and then pressurized with 150 psi H 2 at room temperature. Reactor contents were stirred and heated to 375° C. After achieving 375° C., the final pressure obtained was 2500 psig. Reactor contents were kept at 375° C. and 2500 psig for 1 hour. Although in this example the reactor contents were kept at the reaction conditions for 1 hour other time frames are possible such as from 0.5 to 10 hours, 0.5 to 5 hours or even 1 to 3 hours. After 1 hour, the reactor was cooled and the water vapor, H 2 S and NH 3 gases generated from ammonium tetrathiomolybdate decomposition were removed from the reactor by venting. The resultant MoS 2 catalyst was collected, dried and tested.
  • FIG. 1 depicts the CO conversion rate of Example 1.
  • FIG. 2 depicts the CO conversion rate of a MoS 2 catalyst produced from conventional means.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
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Abstract

A method of producing a MoS2 catalyst. The method begins by the decomposition of ammonium tetrathiomolybdate in an organic solvent. This decomposition is done in the presence of a solution comprising: a solvent and a promoter, and done under gaseous pressure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a non-provisional application which claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/385,856 filed Sep. 23, 2010, entitled “Sulfur-Tolerant Catalyst Prepared Through High Pressure Decomposition,” which is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None
FIELD OF THE INVENTION
A sulfur-tolerant catalyst prepared through high pressure decomposition.
BACKGROUND OF THE INVENTION
The United States natural gas demand is expanding but production is declining and due to that natural gas prices have risen sharply. One method of distributing this energy source is to gasify the coal to produce synthesis gas and then convert it to substitute natural gas via methanation. Current state of the art methanation uses a nickel catalyst which imposes certain operating limitations because of its susceptibility to deactivation by surface carbon and poisoning by surface sulfur.
MoS2 and other sulfur tolerant catalysts based on the transition elements find wide application in the processing of hydrocarbon feedstock's particularly in methanation if they possess sufficient high activity. At present nickel based catalysts are used in methanation because of their high activity, but they are extremely sensitive to deactivation by surface carbon, high temperature and poisoning by various sulfur compounds present in synthesis gas obtained from coal gasification. Sulfur-tolerant MoS2 catalyst can overcome many of the restrictions associated with nickel catalyst. In addition, a recent economic study by Fluor compared sulfur-tolerant methanation with conventional methanation found a 3% reduction in the total plant investment and a 4.5% reduction in the cost of the substitute natural gas plant. The most active sulfur-tolerant catalyst found for methanation in the literature is a MoS2 catalyst initially developed by the Gas Research Institute.
There exists a need to develop a process to create a more active MoS2 catalyst than what is currently available which can be tested in a fixed bed unit and show a high activity for synthesis gas methanation.
SUMMARY OF THE INVENTION
A method of producing a MoS2 catalyst. The method begins by the decomposition of ammonium tetrathiomolybdate in an organic solvent. This decomposition is done in the presence of a solution comprising: a solvent and a promoter, and done under gaseous pressure.
An embodiment is also taught of producing a MoS2 catalyst by first decomposition of ammonium tetrathiomolybdate in an organic solvent in the presence of a solution. The solution contains a solvent of water and a promoter comprising zirconium and elemental sulfur. The temperature of the decomposition is from 275° C. to 475° C. and the pressure the decomposition occurs under a H2 gaseous pressure from 2000 psig to 3000 psig. The MoS2 catalyst has a total CO conversion in synthesis gas methanation greater than 75%.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 demonstrates CO conversion of a MoS2 catalyst wherein the gaseous pressure is greater than 2000 psig.
FIG. 2 demonstrates CO conversion of a MoS2 catalyst produced by conventional means.
 DETAILED DESCRIPTION OF THE INVENTION
The present embodiment describes a method to produce a MoS2 catalyst. The method begins with the decomposition of ammonium tetrathiomolybdate in an organic solvent in the presence of a solution. The solution can contain a solvent and a promoter. In this embodiment the decomposition occurs under gaseous pressure.
A non-limiting example of the solvent used is H2O.
In one embodiment the promoter contains at least one metal and at least one element from group 16. The metal can be a group 4 metal or specifically zirconium. The element from group 16 can be sulfur. Ideally the ratio of the metal to the at least one element is equal to the molar ratio of the desired MoS2 catalyst.
In yet another embodiment the temperature of the decomposition is within the range of supercritical water such as from 275° C. to 475° C.
In an alternate embodiment the gaseous pressure of the decomposition is within the range of supercritical water such as greater than 2000 psig or from 2000 psig to 3000 psig. The gaseous pressure can be from H2 of N2 gas.
The use of a sulfur toleration catalyst shows significant improvements over conventional methanation because the MoS2 catalyst is more carbon and sulfur tolerant. The total CO conversion though use of the present embodiment can achieve in the synthesis gas methanation greater than 75%, 78% or even 80%.
In one embodiment the organic solvent can be any known organic solvent capable of keeping the ammonium tetrathiomolybdate in solution. In one example the solvent can be tridecane.
The MoS2 catalyst methanates the raw syngas directly using equal molar concentrations of carbon monoxide and hydrogen to form carbon dioxide and water and does not need a water gas shift reaction to increase the syngas ratio resulting in steam usage savings. Since the MoS2 catalyst is sulfur tolerant, sulfur impurities have to be removed only to 4 ppm levels instead of conventional 20 ppb levels to fulfill the requirements of pipeline natural gas. This in turn permits the acid gas removal unit to be smaller.
EXAMPLE 1
A MoS2 catalyst was prepared by the decomposition of ammonium tetrathiomolybdate in an organic solvent such as tridecane in the presence of a solvent of water and dimethyl disulfide. In alternate embodiments different types of sulfur can be used as a sacrificial donor to prevent hydrogen from stripping all the sulfur from the MoS2 catalyst in the form of H2S. Other sacrificial sulfur donors that can be used include those commonly known in the art and diethyl disulfide, methyl mercaptan and tetrahydrothiophene.
The method begins by loading a 500 mL autoclave with the catalyst precursor ammonium tetrathiomolybdate (4 mg), 60 grams of the organic solvent of n-tridecane and 50 grams of water. The Mo catalyst was modified with a zirconium promoter by adding 1.776 grams of zirconyl hydrate nitrate. 1 gram of dimethyl disulfide was added to prevent hydrogen from stripping all the sulfur from the MoS2 catalyst. 1.538 grams of elemental sulfur was added for catalyst stability.
The sealed reactor was purged with H2 and then pressurized with 150 psi H2 at room temperature. Reactor contents were stirred and heated to 375° C. After achieving 375° C., the final pressure obtained was 2500 psig. Reactor contents were kept at 375° C. and 2500 psig for 1 hour. Although in this example the reactor contents were kept at the reaction conditions for 1 hour other time frames are possible such as from 0.5 to 10 hours, 0.5 to 5 hours or even 1 to 3 hours. After 1 hour, the reactor was cooled and the water vapor, H2S and NH3 gases generated from ammonium tetrathiomolybdate decomposition were removed from the reactor by venting. The resultant MoS2 catalyst was collected, dried and tested.
To evaluate the catalyst activity, 3.4 of MoS2 catalyst was loaded into a ½ inch stainless steel reactor and the catalyst was evaluated using reaction conditions. For the activity test, a syngas ratio (H2/CO) of 1.08 was selected with a H2 flow at 50.35 cc/min, CO flow at 46.61 cc/min and remaining inerts were substituted with N2 flow at 30.05 cc/min. H2S was flowing at 1 mol % of the feed gas stream. The products formed from the reaction with the MoS2 catalyst were methane and carbon dioxide.
Reactant Mixture
Temperature, ° C. 455
Pressure, PSIG 460
Space Velocity (weight basis) 2400 
H2 37%
CO 34%
N2 28%
H2S  1%
Total CO conversion, % 86.66%  
FIG. 1 depicts the CO conversion rate of Example 1.
FIG. 2 depicts the CO conversion rate of a MoS2 catalyst produced from conventional means.
EXAMPLE 2
The following MoS2 catalysts were produced similarly to example 1, except for a difference with the promoter of zirconium and elemental sulfur. The final CO conversion % was taken 48 hours after the experiment
Total Surface Initial CO Final CO
MoS2 with Pressure Area Conversion Conversion
promoter (psi) (m2/g) (%) (%)
None 1000 202 73 64
Sulfur 1000 47 71 70
Zirconium and 1000 91 83 78
Sulfur
Zirconium 2500 233 86 79
Zirconium and 2500 146 87 78
Sulfur
EXAMPLE 3
The following MoS2 catalysts were produced similarly to example 1, except for a difference of the gaseous component and pressure used to produce the MoS2 catalysts. The final CO conversion % was taken 48 hours after the experiment
Total Surface Initial CO Final CO
Gaseous Pressure Area Conversion Conversion
component (psi) (m2/g) (%) (%)
N2 and H2 1000 23 75 73
H2 1000 66 83 78
H2 1500 86 85 80
H2 2000 130 84 81
H2 2500 146 87 78
Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present invention. Thus the claims are a further description and are an addition to the preferred embodiments of the present invention. The discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application.

Claims (8)

The invention claimed is:
1. A method comprising:
decomposition of ammonium tetrathiomolybdate in an organic solvent in the presence of a solution comprising:
a solvent; and
a promoter comprising zirconium and elemental sulfur,
wherein the decomposition produces a MoS2 catalyst and the decomposition occurs under gaseous pressure.
2. The method of claim 1, wherein the solvent is H2O.
3. The method of claim 1, wherein the temperature of the decomposition is from 275° C. to 475° C.
4. The method of claim 1, wherein the gaseous pressure of the decomposition is greater than 2000 psig.
5. The method of claim 1, wherein the gaseous pressure of the decomposition is from 2000 psig to 3000 psig.
6. The method of claim 1, wherein the decomposition occurs under the gaseous pressure of H2.
7. The method of claim 1, wherein the MoS2 catalyst has a total CO conversion in synthesis gas methanation greater than 75%.
8. A method comprising:
decomposition of ammonium tetrathiomolybdate in an organic solvent in the presence of a solution comprising:
a solvent of water; and
a promoter comprising zirconium and elemental sulfur,
wherein the temperature of the decomposition is from 275° C. to 475° C. and the pressure the decomposition occurs under a H2 gaseous pressure from 2000 psig to 3000 psig,
to produce a MoS2 catalyst having a total CO conversion in synthesis gas methanation greater than 75%.
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Howard S. Meyer, Vernon L. Hill, Ab Flowers, Gas Research Institute, John Happel, Miguel A. Hnatow, Catalysis Research Corporation, "Direct Methanation-A New Method of Converting Synthesis Gas to Substitute Natural Gas", Gas Research Institute, pp. 109-115.

Cited By (4)

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US20120215047A1 (en) * 2011-02-17 2012-08-23 Conocophillips Company Mos2 catalyst for the conversion of sugar alcohol to hydrocarbons
US8673805B2 (en) * 2011-02-17 2014-03-18 Phillips 66 Company MoS2 catalyst for the conversion of sugar alcohol to hydrocarbons
US20140148627A1 (en) * 2011-02-17 2014-05-29 Phillips 66 Company Mos2 catalyst process for the conversion of sugar alcohol to hydrocarbons
US9120986B2 (en) * 2011-02-17 2015-09-01 Phillips 66 Company MOS2 catalyst process for the conversion of sugar alcohol to hydrocarbons

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